Flame retardant polyamide compositions

Abstract

Predominately amino terminated phosphonamide oligomers and their use as flame retardant additives in polyamides and copolyamides without detracting from melt processability are described herein. Other important properties such as strength, modulus, dyeing and thermal stability are maintained.

The invention claimed is: 
     
       1. A polymer composition comprising at least one phosphonamide oligomer of Formula I: 
       
         
           
           
               
               
           
         
         wherein: 
         R is a C 1  to C 20  alkyl or, optionally substituted aryl group; 
         X is an aromatic or aliphatic group; 
         Z is: 
       
       
         
           
           
               
               
           
         
         n is an integer of from 1 to about 20; and 
         one or more polyamides, copolyamides or combinations thereof. 
       
     
     
       2. The composition of  claim 1 , wherein at least 50% of available end groups of the phosphonamide oligomer are amine groups. 
     
     
       3. The composition of  claim 1 , wherein the phosphonamide oligomer comprises a molecular weight of about 200 g/mole to about 10,000 g/mole using polystyrene standards. 
     
     
       4. The composition of  claim 1 , wherein the composition comprises about 2 wt. % to about 50 wt % phosphonamide oligomer. 
     
     
       5. The composition of  claim 1 , wherein the one or more polyamides, copolyamides or combinations thereof are selected from the group consisting of polyhexamethylene adipamide, polyhexamethylene sebacamide, polycaprolactam, and copolyamide 6/66, nylon-4, nylon-6, nylon-6,6, nylon-6,10, nylon-6,9, nylon-6,12, nylon-4,6, nylon-12,12, nylon-11, nylon-12, aromatic polyamides based on m-xylene, diamine and adipic acid; polyamides prepared from hexamethylenediamine and terephthalic acid and/or isoterephthalic acid. 
     
     
       6. The composition of  claim 1 , wherein the one or more polyamides, copolyamides or combinations thereof further comprises monomers derived from ethylene propylene diene monomer (EPDM) or acrylonitrile butadiene styrene (ABS). 
     
     
       7. The composition of  claim 1 , wherein the composition is a homogeneous composition. 
     
     
       8. The composition of  claim 1 , further comprising one or more elastomers. 
     
     
       9. The composition of  claim 8 , wherein the one or more elastomers are selected from the group consisting of poly-2,4,4-trimethylhexamethylene-terephthalamide or poly-m-phenyleneisophthalamide. 
     
     
       10. The composition of  claim 1 , wherein the one or more polyamides, copolyamides or combinations thereof comprise block copolymers. 
     
     
       11. The composition of  claim 10 , wherein the block copolymers comprise one or more polyamides, copolyamides or combinations thereof selected from the group consisting of polyhexamethylene adipamide, polyhexamethylene sebacamide, polycaprolactam, and copolyamide 6/66, nylon-4, nylon-6, nylon-6,6, nylon-6,10, nylon-6,9, nylon-6,12, nylon-4,6, nylon-12,12, nylon-11, nylon-12, aromatic polyamides based on m-xylene, diamine and adipic acid; polyamides prepared from hexamethylenediamine and terephthalic acid and/or isoterephthalic acid, and polyolefins, olefin copolymers, ionomers, chemically bonded or grafted elastomers, or polyethers, polyethylene glycol, polypropylene glycol, or polytetramethylene glycol, or combinations thereof. 
     
     
       12. An article of manufacture comprising a polymer composition comprising at least one phosphonamide oligomer of Formula I: 
       
         
           
           
               
               
           
         
         wherein: 
         R is a C 1  to C 20  alkyl or, optionally substituted aryl group; 
         X is an aromatic or aliphatic group; 
         Z is: 
       
       
         
           
           
               
               
           
         
         n is an integer of from 1 to about 20; and 
         one or more polyamides, copolyamides or combinations thereof. 
       
     
     
       13. The article of manufacture of  claim 12 , wherein the article is selected from the group consisting of free standing films and sheets, fibers, foams, molded articles, coated substrates, adhesives, and fiber reinforced composites. 
     
     
       14. The article of manufacture of  claim 12 , wherein the article is selected from electronics, automotive parts, fabrics used to make clothing or furnishings, carpet fiber, apparel, upholstery, airbags, tires, conveyor belts, and hoses.